Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service. This module cannot possibly anticipate all such variations and provide advice or caution to each. Accordingly, anyone who departs from the instruction provided in this module must first establish that they compromise neither their personal safety nor the vehicle integrity by their choice of methods, tools or parts. The following list contains general warnings that should always be followed while working on a vehicle. • Always wear safety glasses for eye protection. • Use safety stands whenever a procedure requires underbody work. • Be sure the ignition switch is always off unless otherwise specified by a procedure. • Set the parking brake when working on the vehicle. • Operate the engine only in a well ventilated area. • Keep clear of moving parts when the engine is running. • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. • Do not smoke while working on a vehicle.
Trang 1Optima Hybrid Technology (HEV)
Course Guide
Course Guide
Student GuideOHEV.01
Trang 2SAFETY FIRST
Appropriate service methods and proper repair procedures are essential for safe,
reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service This module cannot possibly anticipate all such variations and provide advice or caution to each Accordingly, anyone who departs from the instruction provided in this module must first establish that they compromise neither their personal safety nor the vehicle integrity by their choice of methods, tools or parts The following list
contains general warnings that should always be followed while working on a vehicle.
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires underbody work.
• Be sure the ignition switch is always off unless otherwise specified by a procedure.
• Set the parking brake when working on the vehicle.
• Operate the engine only in a well ventilated area.
• Keep clear of moving parts when the engine is running.
• To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.
• Do not smoke while working on a vehicle.
This course requires the student/technician to work closely with a high voltage battery.
In order to maximize safety, the student/technician will be required to remove all lic objects on your person, including but not limited to watches, body piercings, pins, buttons, bracelets, etc, in order to reduce the risk of electrical arcing and potential elec- trocution In addition, those students/technicians who use metallic medical devices, such as pacemakers, insulin pumps, etc., should be aware of the potential risks of work- ing closely with a high voltage battery.
metal-Within this module you will find Notes, Cautions and Warnings which provide critical information and help you do your job safely and efficiently When you see a Note,
Caution or Warning, be certain you understand the message before you attempt to form any part of a service procedure.Below are the definitions of these terms.
WARNING
A Warning alerts you to the highest level of risk Warnings inform you that a procedure must be done in a particular way to minimize the chances of an accident that could result in personal injury or even loss of life.
!
!
Trang 3The content of this course is intended for informational and educational purposes only Any reliance placed on such information is therefore strictly at your own risk In no event will Kia Motors America, Inc ("KMA") or Kia University be liable for any loss or damage including, without limitation, indirect or consequential loss or damage, property loss, damage, personal injury or death caused to any persons arising out of or in connection with the
use of this course.
While KMA makes all reasonable efforts to ensure that all course materials are correct, accuracy cannot be anteed and KMA does not assume any responsibility for the accuracy, completeness, or authenticity of any infor- mation contained in these course materials Nothing in this course is intended as a guarantee of success The content of this course is intended for informational and educational purposes only Any reliance placed on such information is therefore strictly at your own risk In no event will Kia Motors America, Inc (“KMA”) be liable for any loss or damage including without limitation, indirect or consequential loss or damage, or any loss or dam- age whatsoever arising from loss of data or profits arising out of, or in connection with the use of this course.
While KMA makes all reasonable efforts to ensure that all course materials are correct, accuracy cannot be anteed and KMA does not assume any responsibility for the accuracy, completeness, or authenticity of any infor- mation contained in these course materials All information contained herein was accurate and correct at the time
ate any warranties, either expressed or implied to any Kia products.
Reproduction of the contents of this material without the expressed written approval of KMA is prohibited.
© 2011 Kia Motors America, Inc All Rights Reserved.
Trang 4TT-OHEV211-IL-CG012nd Printing - March 2011
Trang 5OHEV Course Guide 01 1
Optima Hybrid Technology
OPTIMA HYBRID TECHNOLOGY
Course Guide COURSE OVERVIEW
The goal of this course is to increase a technician’s efficiency and productivity through a thorough understanding of the High Voltage (HV) system and safety procedures required to service the vehicle to meet customer expectations for a first visit fix
Critical service topics include:
x Proper use of personal protection equipment (PPE)
x Safely disabling the HV system
x Key HEV components and subsystems
x Tools necessary for safely repairing the HV system
x Service procedures include:
o Safety Plug Removal and Installation
x Safely disable the HV system
x Inspect, measure, and evaluate HEV components
x Analyze electrical schematics on selected HEV circuits
x Use of Hybrid special service tools
x Calibrate specific Hybrid components
x Use the GDS to perform service procedures and test specific Hybrid systems
In this course, you will be expected to use personal protection equipment, follow diagnostic procedures and instructions to safely service and gain a technical
understanding of HEV systems and their operation
Trang 6PERFORMANCE SCORECARD
SCORECARD ROUTING
The target audience for this course consists of Kia Dealership Technicians who have an advanced understanding of electrical systems, diagnosis, and have successfully completed the prerequisites
The following prerequisites must be completed prior to the start of this course:
x Diagnosing with GDS VE (GDS6) ILC or equivalent
x Auto Electrical Diagnosis ILC (AED)
x Introduction to Hybrid Safety Web based course (IHS)
x Hybrid Technical Highlights Web based course (HTH) Kia University has adopted a training delivery system where you will need to successfully pass prerequisite courses containing knowledge that supports the course The course contains safety, system theory, and
operation with tasks to practice what you have learned concluding with a Performance Assessment
A Theory Module presents information to increase
your working knowledge of the subject, which helps guide you to successful diagnosis and repair
The Guided Practice Module allows you the
opportunity to practice diagnostic skills through
hands-on experience The tasks are instructor supervised and verified
The Performance Assessment Module provides you
the opportunity to demonstrate what you have learned
A final score of 80% or higher is required to pass this course
The Performance Scorecard is used to track your performance on guided practices, diagnosis &
troubleshooting, and written knowledge assessments One copy of the scorecard is yours, and one copy is used to update your Kia technical training records
Should you not complete the course, the third copy is forwarded to your Kia District Parts and Service
ANSWER SHEET An answer sheet is provided to record your
Performance Assessment answers You will return your answer sheet to your instructor for grading Your score will be transferred to the scorecard
Trang 7OHEV Course Guide 01 3
Optima Hybrid Technology
COURSE MATERIAL/TIMELINE
Module Number Module Title Theory Guided Practice Performance Assessment Course Day Course Timeline
02 Intro Optima HEV & Safety X 1 8:30 – 10:00 am
03 Intro Optima HEV & Safety X 1 10:00 – 10:45 am *
04 Battery System & Electric Motor X 1 10:45 – 2:00 pm *
05 Battery System & Electric Motor X 1 2:00 – 3:00 pm *
06 Hybrid Power Control Unit X 1 3:00 – 5:00 pm
06 Hybrid Power Control Unit Cont X 2 8:30 – 9:30 am
07 Hybrid Power Control Unit X 2 9:30 – 11:00 am *
08 Hybrid Engine & Transaxle X 2 11:00 – 2:00 pm *
09 Hybrid Engine & Transaxle X 2 2:00 – 3:30 pm *
10 Hybrid Auxiliary Systems X 2 3:30 – 5:00 pm
11 Hybrid Auxiliary Systems X 3 8:30 – 9:30 am
12 Active Hydraulic Booster X 3 9:30 – 11:00 am *
13 Active Hydraulic Booster X 3 11:00 – 12:00 pm *
14 Performance Assessment (PA) X 3 12:00 – 3:00 pm *
*Includes Break and Lunch
**Kia recent TSBs and service information
Beginning of each day begins with a review of modules completed the previous day
Trang 8ICONS
The course and its materials are here for you to learn and keep Use them and your time in a way that will benefit you when you return to your dealership
Make drawings, jot down notes, and highlight these materials to help you remember important details Each module is designed with ample margins for your
important notes
If you do not understand something in this course, ask
your instructor for clarification Asking questions is
strongly encouraged to help you get the most out of this course
During the hands-on activities, you will often be working as a team By actively engaging in each activity, you will maximize your learning experience While in the lab, feel free to ask the instructor questions at any time
This course is an opportunity for you to learn in a controlled environment under the guidance of a trained Kia instructor Through active participation you can build confidence in your abilities to diagnose customer concerns right the first time, every time!
The Reference Icon indicates you must refer to
additional publications in order to complete the questions or activity
The Activities Icon indicates an activity that supports
a critical learning objective These activities are offered
to help you master the material
The Feedback Icon indicates a progress check meant
to provide you with feedback on your understanding of the course material
The STOP Icon indicates you must STOP the activity
Do not proceed until instructed to continue
Trang 9Optima Hybrid Technology (HEV)
Theory Module
Introduction to Optima
HEV & Safety
Student GuideOHEV.02
Trang 10SAFETY FIRST
Appropriate service methods and proper repair procedures are essential for safe,
reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service This module cannot possibly anticipate all such variations and provide advice or caution to each Accordingly, anyone who departs from the instruction provided in this module must first establish that they compromise neither their personal safety nor the vehicle integrity by their choice of methods, tools or parts The following list
contains general warnings that should always be followed while working on a vehicle.
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires underbody work.
• Be sure the ignition switch is always off unless otherwise specified by a procedure.
• Set the parking brake when working on the vehicle.
• Operate the engine only in a well ventilated area.
• Keep clear of moving parts when the engine is running.
• To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.
• Do not smoke while working on a vehicle.
This course requires the student/technician to work closely with a high voltage battery.
In order to maximize safety, the student/technician will be required to remove all lic objects on your person, including but not limited to watches, body piercings, pins, buttons, bracelets, etc, in order to reduce the risk of electrical arcing and potential elec- trocution In addition, those students/technicians who use metallic medical devices, such
metal-as pacemakers, insulin pumps, etc., should be aware of the potential risks of working closely with a high voltage battery.
Within this module you will find Notes, Cautions and Warnings which provide critical information and help you do your job safely and efficiently When you see a Note,
Caution or Warning, be certain you understand the message before you attempt to form any part of a service procedure.Below are the definitions of these terms.
WARNING
A Warning alerts you to the highest level of risk Warnings inform you that a procedure must be done in a particular way to minimize the chances of an accident that could result in personal injury or even loss of life.
!
!
Trang 11The content of this course is intended for informational and educational purposes only Any reliance placed on such information is therefore strictly at your own risk In no event will Kia Motors America, Inc ("KMA") or Kia University be liable for any loss or damage including, without limitation, indirect or consequential loss or damage, property loss, damage, personal injury or death caused to any persons arising out of or in connection with the use
of this course.
While KMA makes all reasonable efforts to ensure that all course materials are correct, accuracy cannot be anteed and KMA does not assume any responsibility for the accuracy, completeness, or authenticity of any infor- mation contained in these course materials Nothing in this course is intended as a guarantee of success The content of this course is intended for informational and educational purposes only Any reliance placed on such information is therefore strictly at your own risk In no event will Kia Motors America, Inc (“KMA”) be liable for any loss or damage including without limitation, indirect or consequential loss or damage, or any loss or dam- age whatsoever arising from loss of data or profits arising out of, or in connection with the use of this course.
While KMA makes all reasonable efforts to ensure that all course materials are correct, accuracy cannot be anteed and KMA does not assume any responsibility for the accuracy, completeness, or authenticity of any infor- mation contained in these course materials All information contained herein was accurate and correct at the time
ate any warranties, either expressed or implied to any Kia products.
Reproduction of the contents of this material without the expressed written approval of KMA is prohibited.
© 2011 Kia Motors America, Inc All Rights Reserved.
Trang 12TT-OHEV211-IL-TH032nd Printing - March 2011
Trang 13Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 1
INTRODUCTION TO HEV AND SAFETY
Theory
MODULE GOAL Upon completion of this module, technicians will be
able to identify hybrid vehicle components, operation, driving modes, and safety procedures
MODULE OBJECTIVES Upon completion of this module, technicians should be
able to:
x Identify HEV components
x Identify HEV driving modes
x List safety equipment
x Perform high voltage glove inspection
x List safety procedures
MODULE INSTRUCTIONS This theory module will conclude with progress check
questions that will assess what technicians have learned
Pay attention, ask questions, and participate to get the most out of this module
TARGET AUDIENCE The target audience for this module consists of Kia
dealership technicians who will service, diagnose, and repair the Kia Optima Hybrid
REQUIRED MATERIALS To complete this module, the following items will be
needed:
x Optima Hybrid Vehicle
x High Voltage Safety Gloves (Class 0)
x Safety Glasses
x Roof Safety Topper
x DVOM (CAT III)
TIME TO COMPLETE Approximately 90 minutes
Trang 14ACRONYMS
AAF Active Air Flaps
ABS Anti-lock Brake System
AHB Active Hydraulic Booster
ASP Absolute Steering Position
BAU Brake Actuation Unit
BCM Body Control Module
BMS Battery Management System
CAN Controller Area Network
CLUM Cluster Module
CPS Clutch Pressure Sensor
ECM Engine Control Module
E-COMP Electric A/C Compressor
ECU Electronic Control Unit
EOP Electric Oil Pump
EPS Electric Power Steering
ESC Electronic Stability Control
EWP Electric Water Pump
EV Electric Vehicle
FATC Fully Automatic Temperature
Control
HCU Hybrid Control Unit
HEV Hybrid Electric Vehicle
HPCU Hybrid Power Control Unit
HPU Hydraulic Power Unit
HSG Hybrid Starter Generator
HV High Voltage
HWP Heater Water Pump IGBT Insulated Gate Bipolar Transistor LDC Low DC-DC Converter
LiPB Lithium-ion Polymer Battery MCU Motor Control Unit
MDPS Motor Driven Power Steering NVH Noise Vibration Harshness
NVLD Natural Vacuum Leak Detection OPU Oil Pump Unit (module)
PAG Polyalkylene Glycol PCM Powertrain Control Module
PRA Power Relay Assembly PTS Pedal Travel Sensor PVE Polyvinyl ether
PWM Pulse Width Modulated SAS Steering Angle Sensor
SJB Smart Junction Box
SMK Smart Key Module
SOC State of Charge
SSB Start/Stop Button
SST Special Service Tool TCM Transmission Control Module
TCS Traction Control System
TMED Transmission Mounted Electric
Device
Trang 15Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 3
INTRODUCTION
WHAT IS AN HEV? A Hybrid Electric Vehicle (HEV) is defined as a vehicle
that utilizes power from both an engine and an electric motor to achieve higher fuel efficiency when compared
to a similar engine-only vehicle
The Kia HEV is driven by 2 power sources:
x A 2.4L Theta II MPI engine
x A 30 kilowatt electric motor (40 horsepower)
PARALLEL TYPE The Kia HEV is considered a parallel-type system
The Kia parallel-type system utilizes a Transmission Mounted Electric Device (TMED)
The engine and drive line are mechanically connected,
so the system requires a transmission
The motor in this TMED type is directly connected to the transmission and is separated from the engine
There is a clutch between the engine and the motor
This separation allows for an electric-only drive mode
It is also known as a full- or hard-type hybrid system, which allows driving on electric motor power without the need for the engine
Trang 16COMPONENTS
The main components of the Optima hybrid system are:
x Theta-II 2.4 MPI Atkinson Cycle Engine
x 6 Speed Automatic Transaxle
x Electric Motor & Hybrid Starter Generator (HSG)
x High Voltage Battery Assembly
x Hybrid Power Control Unit (HPCU)
o HCU (HEV System Control Unit)
o LDC (Low DC-DC Converter)
o MCU (Motor Control Unit, or Inverter)
x Active Hydraulic Booster (AHB)
x Electric A/C Compressor
x Transaxle Electric Oil Pump (EOP)
x Active Air Flap (AAF)
x Hybrid Cluster (CLUM)
Trang 17Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 5
x An increased compression ratio
x Pistons are changed to reduce combustion chamber volume
x Thermostat opening temperature is increased to 88°C (190°F) from 82°C (180°F)
x Lighter valve springs
x Piston rings are coated with low-friction material
Trang 18HYBRID AUTOMATIC TRANSAXLE
The hybrid vehicle uses a 6-speed automatic transaxle
The torque converter has been removed and the hydraulic engine clutch and torsion damper installed in its place
An electric oil pump is mounted on the side of the transaxle to generate required hydraulic pressure for transaxle shifting and engine clutch operation during low speed driving or Electric Vehicle (EV) mode, in which the vehicle operates only on the electric motor while the engine is stopped
Trang 19Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 7
MOTORS
ELECTRIC MOTOR The electric drive motor installed in the hybrid has a
maximum power output of 30 kilowatts (40 hp)
In Electric Vehicle (EV) mode, the electric motor provides the power necessary to move the vehicle without using the engine
In hybrid mode, the electric motor assists engine power and recharges the high voltage battery during
regenerative braking
HYBRID STARTER
GENERATOR
The Hybrid Starter Generator (HSG) assembly rated at
@ 8.5 kilowatts (11 hp) allows the hybrid to switch between Electric Vehicle and hybrid modes
It cranks the engine for starting, and acts as a generator to charge the high voltage battery when the state of charge (SOC) is below a specified value
Stator Coil
Permanent Magnet Armature
Trang 20x Power Relay Assembly (PRA)
x Battery Management System (BMS) module
x Air cooling system
In addition, active protection devices such as the Power Relay Assembly and fuses improve reliability and
durability
For safety, the high voltage battery assembly uses a battery current check circuit, which shuts off electric current in case of over-charge
If a system fault occurs, the BMS turns off the Power Relay Assembly to protect the hybrid system
The BMS module maintains the optimal performance of the high voltage battery
The BMS measures the current, voltage and temperature of the battery and calculates the high voltage battery SOC
The BMS controls the air cooling system used to maintain optimal battery temperature by passing cool air through the battery case
The BMS performs the cell balancing control, which minimizes voltage deviation of each cell during battery charging and discharging
Trang 21Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 9
MOTOR CONTROL UNIT
MOTOR CONTROL UNIT The Motor Control Unit (MCU) is a combination inverter
LOW VOLTAGE
DC TO DC CONVERTER
In the HEV, the Low Voltage DC to DC Converter (LDC) reduces the voltage from the high-voltage battery to 12 volts, supplying power to electric devices and charging the auxiliary battery
In conventional vehicles, the alternator supplies power
to electric devices and charges the battery
Trang 22ACTIVE AIR FLAP
The hybrid uses an active air flap mounted between the grille and the radiator
Flap opening is controlled according to driving conditions
The flap closes while driving to reduce air resistance
When the engine temperature increases, the flap opens
to reduce the engine room temperature
Engine coolant temperature, A/C pressure, and vehicle speed are transmitted via CAN communication to the smart actuator, which opens and closes the flap
Trang 23Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 11
ACTIVE HYDRAULIC BOOSTER
Because the engine does not run all the time, it does not use a vacuum booster
An Active Hydraulic Booster (AHB) system replaces the vacuum booster
To provide normal brake pedal feel, the system uses a brake pedal simulator and pedal travel sensor
Vehicle braking uses both hydraulic braking and regenerative electric motor braking
Trang 24ELECTRIC A/C COMPRESSOR
An electric compressor is used to ensure continued operation of the A/C, even when the engine stops
It is divided into three-sections:
x Compressor
x Motor
x Inverter When the A/C is selected, the FATC sends an operation authorization request to the HCU
The HCU then sends a signal with the allowable electric power amount back to the FATC
The FATC operates the electric compressor within the allowable electric power range
Trang 25Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 13
POWER FLOW
ENGINE CRANKING The Hybrid Starter Generator (HSG) is connected to the
crankshaft with a drive belt and is used to start the engine
Two (2) auto tensioners provide belt tension
In the event of HSG failure or if the drive belt is broken, the engine is started by the electric motor
EV DRIVING If the state of charge of the high voltage battery is
normal, only the electric motor power is used when the vehicle starts to move or during low-speed driving
While the engine is OFF, the transaxle’s hydraulic pressure is generated by the EOP
Trang 26POWER FLOW cont
ENGINE-ONLY DRIVING In the engine-only driving mode, only engine power is
used while driving
The engine clutch is engaged to transfer engine power
to the transmission
HEV DRIVING POWER ASSIST BY MOTOR
During acceleration, the electric motor is used to assist the engine for more power and increased torque
Trang 27Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 15
POWER FLOW cont
HEV DRIVING MOTOR CHARGING
When the state of charge of the high voltage battery is low, the electric motor is used to charge the high voltage battery with engine power while driving
REGENERATIVE BRAKING Regenerative braking is used to convert kinetic energy
into electric energy when the vehicle decelerates to charge the high voltage battery
Trang 28POWER FLOW cont
IDLE CHARGING When the state of charge of the high voltage battery is
low, the engine runs at idle when the vehicle is stopped
to charge the battery
The HSG is used as the generator after engine startup
The generated AC voltage passes through the MCU and is converted to DC voltage, which is supplied to the high voltage battery
IDLE STOP If the state of charge of the high voltage battery is
normal, the engine turns off when the vehicle comes to
a stop
The vehicle is powered only by the electric motor when
it starts to move, and the engine is not restarted until needed for power or charging the high voltage battery
Trang 29Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 17
CAN COMMUNICATION
Dual CAN: Hybrid CAN and Chassis CAN
Several control devices are connected to the speed CAN in the HEV
high-The HEV uses a Dual High Speed CAN (Hybrid CAN + Chassis CAN) for communication
The vehicle-drive-related systems connected to the Hybrid CAN include the HPCU, PCM, and BMS
The remaining systems communicate on the Chassis CAN
The GDS connects to the Dual High Speed CAN for diagnosis
Trang 30You are free to handle the components on the benches
except the high voltage battery (just look) We
encourage you to pick up parts, pass them around, and discuss your findings with other technicians
Pursue your curiosity, ask your instructor questions, and seek new knowledge and clarification in order to gain the greatest benefit out of this session
WARNING: Do not touch the High Voltage Battery
Assembly
WARNING: Do not touch any of the components under
the hood or in the trunk area
Trang 31Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 19
SAFETY
HIGH VOLTAGE SAFETY Your safety is Kia’s utmost concern
WARNING: The Optima HEV contains several systems
that can cause severe bodily injury or even death
All components that use high voltage are marked with High Voltage Warning Labels and have distinct orange and yellow markings on them
All high voltage wiring is protected in orange covering to distinguish it from other wiring on the vehicle
WARNING: Do not touch any of the high voltage
harnesses or connectors without first properly disabling the high voltage system Refer to the Optima Hybrid Service Information for detailed instructions
x Remove any metallic items from your body when working with high voltage (watches, rings, metallic pens, etc.)
You are required to use specialized safety equipment when working on high voltage systems
These include the following:
x High Voltage Insulating Gloves (Class 0) with leather protectors
x DVOM (CAT III) 1000 V rating
x Safety Glasses
x Insulated Tool Kit
x High Voltage Warning Vehicle Topper
Trang 32It is recommended that you wear leather glove covers
to protect the rubber insulating gloves
The rubber insulating gloves have a shelf life of one (1) year unopened, and must be recertified electrically or replaced at least once every six (6) months after the package is opened
WARNING: Always use rubber insulating gloves in the
proper class (class 0) and read all safety warnings provided by the manufacturer
WARNING: Rubber insulating gloves contain natural
rubber latex, which may cause allergic reactions Do not expose this product to any persons known or suspected to be latex sensitive without consulting with a physician
Trang 33Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 21
SAFETY GLASSES Safety glasses should be worn at all times when
working on any vehicle
The safety glasses must be rated ANSI Z87.1-2003 with side shields
Trang 34SAFETY cont
INSULATED TOOLS Use the insulated hand tools when servicing high
voltage electrical connections and when indicated in the service information
HIGH VOLTAGE TOPPER The “DANGER!” topper needs to be placed on the roof
of the vehicle any time the high voltage system is being serviced and there is a possibility someone may come
in contact with high voltage connections or terminals
Trang 35Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 23
DISABLING THE HIGH VOLTAGE SYSTEM
WARNING: Before attempting any repairs of the high
voltage system, you must first disable the high voltage system by removing the Safety Plug, following the
procedure listed below
REMOVING THE SAFETY PLUG
While servicing the high voltage circuit, you must follow the procedures listed below
1 Ignition in OFF mode
2 While wearing rubber insulating gloves, remove the negative terminal connector on the 12 V auxiliary battery
3 Remove the Safety Plug access cover located in the trunk
4 Remove the Safety Plug by lifting the lock release, then pull the latch down 90 degrees and remove by pulling on the grip Place the Safety Plug in a secure location to prevent accidental reinstallation of the Safety Plug
CAUTION: Wait a minimum of five (5) minutes before
proceeding with the voltage check at the PRA or handling any high voltage devices after removing the safety plug
NOTE: The five (5) minute wait time is to ensure the
high voltage in the inverter capacitor is discharged
Trang 36CHECKING HIGH VOLTAGE CIRCUIT
PRA
(INV + /-)
1 and 2 IGN OFF : 0V
IGN ON : 270V (198V~309V)
5 Remove the back support of the rear seat
6 Using insulated tools and PPE, remove the PRA assembly access cover
7 Using a CAT III DVOM, measure the two exposed high voltage battery terminals to ensure the voltage
is below 30 Vdc before starting any work
NOTE: For extra precaution, keep one hand behind
your back while taking high voltage measurements
This is referred to as the One Hand Rule
SERVICING THE HIGH
VOLTAGE SYSTEM
When servicing the high voltage system, voltage must
be less than 30 Vdc when measured at the positive and negative terminals of the PRA
CAUTION: When measuring high voltage, be cautious,
and wear rubber insulating gloves at all times
Trang 37Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 25
WARNING: If the measured voltage is more than 30 Vdc,
check to be sure the Safety Plug has been properly removed
If, after verification of the Safety Plug removal, the voltage remains above 30 Vdc, a serious high voltage
system fault exists Do Not Continue with any high
voltage system repair Use the GDS to check all systems for DTCs Refer to the DTC guide for diagnosis If no DTCs are found, contact TechLine for assistance
SAFETY PLUG CIRCUIT The Safety Plug has two circuits:
x Safety Plug Signal
x Safety Plug Power When the Safety Plug is removed, it opens the high voltage battery circuit between main battery module 5 and 6
The Safety Plug also contains a 125 Amp fuse to shut down the system in case of a short to ground in the main battery circuit
Trang 38HIGH VOLTAGE SAFETY SUMMARY
PRE-TASK PREPARATION x Check rubber insulating gloves and safety glasses
x Place the “DANGER!” High Voltage Vehicle Topper
on the vehicle roof
x Always be aware of your surroundings while working
on high voltage systems
x Wear rubber insulating gloves when handling high voltage components, and ensure that the high voltage Safety Plug has been removed and placed
in a secure location
x When working on metallic parts of the high voltage cable (orange color), always check with a DVOM to ensure that it is below 0.1 Vdc when measured to ground
x Do not touch any high voltage cables when the insulation cover is removed
x If about half of the vehicle height is under water, do not touch the Safety Plug or go near it
x If the Safety Plug must be touched, only do so after moving the vehicle out of the water and parking it in
a safe location
x In case of leakage of electrolytes from the high voltage battery, do not touch the electrolyte In the event of contact with the electrolyte, thoroughly wash the skin contact area with soap and water
x If high voltage needs to be cut off as a result of vehicle damage, comply with the following procedure:
o Turn the vehicle OFF by pressing the Start/Stop Button
o Remove the key fob from the vehicle and remove the negative battery cable from the auxiliary battery
o While wearing rubber insulating gloves, remove the Safety Plug
Trang 39Optima Hybrid Technology
Introduction to HEV and Safety – Theory 02 27
PROGRESS CHECK QUESTIONS
1 What two power sources drive the Optima Hybrid?
a 2.4L Gasoline Direct Injection (GDI) and Hybrid Starter Generator (HSG)
b 2.7L MPI V6 and 30 Kilowatt electric motor
c 2.7L MPI V6 and 270 Kilowatt battery
d 2.4L Theta II MPI and 30 Kilowatt electric motor
2 Which type of hybrid system is used in the Optima Hybrid?
a Parallel system, TMED, Full/Hard type
b Series system, TMED, Full/Hard type
c Parallel system, EMED, Soft/Mild type
d Series system, EMED, Soft/Mild type
3 Which of the following components are used in the hybrid system?
a Electric A/C Compressor
b Active Hydraulic Booster
c Both a and b
d Neither a nor b
4 The electric motor functions in which of the following modes?
a Moves the vehicle without using the engine
b Assists the engine to move the vehicle
c Recharges the high voltage battery during regenerative braking
d All of the above
5 Which of the following components are not part of the high voltage battery assembly?
a Power Relay Assembly (PRA)
b Battery Management System (BMS) module
c Hybrid Power Control Unit (HPCU)
d Air Cooling Blower Motor
Trang 406 What best describes high voltage cables and wiring?
a They have a label attached indicating high voltage
b They glow using ultraviolet light
c They are wrapped in caution tape
d They are covered in orange conduit and tape
7 When must rubber insulating gloves be inspected?
a Once every six (6) months
b Once every year from date of manufacture
c Once every week
d Before every use
8 When must the Safety Plug be removed?
a When performing regular scheduled service
b Before attempting any repairs of the high voltage system
c When replacing the auxiliary battery
d When performing PDI
9 What is the minimum required amount of time to wait after removing the Safety Plug before measuring the PRA output voltage?